Polymerization catalyst and method for the polymerization of olefins



United States Patent US. Cl. 260-8018 13 Claims ABSTRACT OF THE DISCLOSURE Coordination-type polymerization catalyst, especially for making EPR or EPDM, based on (1) a vanadium salt and (2) an alkylaluminum halide, is activated (made more elficient, or revived after it has become exhausted) by adding (3) a nitroso compound (e.g., p-dimethylaminonitrosobenzene) or a quinone (e.g., tetrachloro-p-benzoquinone). The activator (3) also acts as a regulator of molecular weight.

This application is a continuation-in-part of my copending application Ser. No. 304,691, filed Aug. 26, 1963, now abandoned.

This invention relates to improved catalysts for the polymerization of olefins, and methods for the polymerization of olefins using these improved catalysts. More par ticularly the invention comprises catalysts obtained by the interaction of (1) A vanadium salt,

(2) An organometallic compound of a type represented by the formulae (a) RMgX (Grignard reagent), where R is a hydrocarbon radical having from 1 to 12 carbon atoms, e.g., an alkyl radical such as methyl, ethyl, etc. or an aryl radical such as phenyl, naphthyl, etc., and X is a halogen atom,

(b) LiAlR where R is as above defined, and

(c) R AI X where R and X are as above defined, A is a number from 2 to 6, B is a number from zero to 4, and A-l-B=6, and

(3) A material selected from the group consisting of (a) Nitroso compounds, and

'(b) Quinones, at least one of the substances (1) and (2) containing at least one halogen atom.

In the following, chemicals (1) and (2), i.e., the vanadium salt, and the Grignard reagent or the organoaluminum compound, or their interaction product, will frequently be referred to as the primary catalyst system, and chemical (3) will be referred to as the activator or, sometimes, as the regulator.

The invention has particular reference to the use, along with the described primary catalyst ingredients (1) and (2), of an additional chemical (3), as defined above, which has the surprising eifccts of (A) activating the catalyst and (B) serving as a regulator of molecular weight of the polymer. The invention comprises any method by which the chemical (3) is reacted with the reaction product of (l) and (2) in the presence of the monomer or monomers. In this way it is ensured that catalyst activation and/ or molecular weight regulation of the polymer is achieved.

Polymerization catalysts which are the interaction products of (l) a compound of a metal of Groups IV-B and VB of the periodic table of the elements (see Handbook of Chemistry and Physics, 41st Edition, pages 4489, published by Chemical Rubber Publishing Company, Cleveland, Ohio) and (2) an organometallic compound of a metal of Group III-A of the periodic table are well known through patents and other publications of recent years. Some of these disclosures, such as Schreyer, US. 2,962,451, and Ziegler, Belgian Patent 553,655 show catalysts falling within the scope of the primary catalyst systems of the present invention. Schreyer, among others, shows catalysts comprising a vanadium salt and an alkylaluminum halide, for the polymerization of ethylene or propylene. Ziegler shows catalysts from VOCl trialkylaluminum for the copolymerization of ethylene with higher alpha-olefins. Sometimes the catalysts are insoluble or heterogeneous, and sometimes they are soluble, depending on the exact composition.

The abovedescribed prior catalyst systems, and indeed all other prior art catalysts of this type known to the present inventor, are deficient in that: (a) they show a low catalyst efiiciency (here expressed as weight of polymer produced per unit weight of vanadium compound per unit time); (b) the polymerization rate is undesirably slow unless relatively high concentrations of catalyst are used; and, (c) in the case of a soluble catalyst, the activity decreases, oiten rapidly, during the course of the polymerization. These deficiencies are more serious in the copolymerization of ethylene with propylene or with other olefins having more than two carbon atoms, than in the homopolymerization of ethylene. Furthermore, conventional catalyst systems frequently do not afford an opportunity to regulate or modify the molecular weight of the polymer, especially when only moderate concentrations of catalyst are used.

In British Patent 886,368, United States Rubber Company, published Jan. 3, 1962, improved catalyst systems using VCL, or VOCl with either dialkylaluminum halide or alkylaluminum dihalide, or mixtures of the two, are disclosed which show a catalyst efficiency in the copolymerization of ethylene and propylene 10-100 times as great ts that of the aforementioned prior art catalysts. Even the improved catalysts of British Patent 886,368 are amenable to substantial further improvement by the addition of the activators or regulators of the present invention, especially as regards the maintenance of catalytic activity over a relatively long period of polymerization, and as regards the production of polymer of low molecular weight.

The present invention is directed to making more effective and more eflicient a primary catalyst system comprising a vanadium salt (1) and an organometallic material (2), as defined previously, by the combination therewith of an activator/regulator (3) selected from the following types of compounds:

(a) nitroso compounds, of which typical examples are: aryl nitroso compounds, e.g., p-nitrosodimethylaniline (also called p-dimethylaminonitrosobenzene), 4-nitrosodiphenylamine, nitrosobenzene, o-nitrosotoluene, etc., and N-nitrosoamines, e.g., N-nitrosodiphenylamine, N-nitroso- N-methylaniline, N,4-dinitroso-N-methylaniline, etc., and

(b) quinones, e.g., p-benzoquinone, tetrachloro-p-benzoquinone (chloranil), 1,4-naphthoquinone, 2,6-naphthoquinone, 2,3 dichloronaphthoquinone, 9,10 anthraquinone, substitution products of the above, beta-methylanthraquinone, and l,2-quinones such as 1,2-naphthoquinone, o-benzoquinone, acenaphthenequinone and phenanthrenequinone, and the like.

The olefins which are polymerized by' the present process include ethylene, propylene, and similar alpha-olefins, having the formula CH =CHR in which R is hydrogen or a hydrocarbon radical having from 1 to 8 carbon atoms. Examples of such olefins include, e.g., butene-l, hexene- 1, 4 methylpentene-l, S-methylhexene-l, and 4-ethylhexene-l.

A preferred form of the invention is directed to the copolymerization of ethylene and propylene to yield 3 rubbery products. An especially preferred practice of the invention contemplates the production of unsaturated, sulfur-vulcanizable, rubbery terpolymers of ethylene, propylene and a diene such as dicyclopentadiene, methylcyclopentadiene dimer, 1,4-hexadiene, 11-ethyl-1,11-tridecadiene, 1,9-octadecadiene, 1,5-cyclooctadiene, or other suitable copolymerizable dienes such as are disclosed in British Patent 880,904 to Dunlop Rubber Co., Oct. 25, 1961; US. 2,933,480 to Gresham and Hunt, Apr. 19, 1960; US. 3,000,866 to Tarney, Sept. 19, 1961; and Belgian Patents 623,698 and 623,741 to Montecatini, Feb. 14, 1963. These disclosures are herewith incorporated by reference. Preferred terpolymers contain from about 1 to about 25% (more preferably about 2% to about by weight of dicyclopentadiene or the like. The remaining portion of the interpolymer generally contains from about 25% to about 75 by .weight of propylene, the remainder being ethylene.

The primary catalyst system which is to be activated in accordance with the method of my invention comprises, as indicated previously, a reaction product of (1) a vanadium salt and (2) a Grignard reagent or an organoaluminum compound. Among the vanadium salts which may be used, there may be mentioned vanadium halides, oxyhalides, a'lkoxides and acety-lacetonates. Specific examples of these salts are vanadium dichloride, vanadium trichloride, vanadium tetrachloride or tetrabromide, vanadium oxydichloride, vanadium oxytrichloride, alkyl vanadates (especially where the alkyl group contains 1-12 carbon atoms, e.g., n-butyl vanadate), vanadyl or vanadium acetylacetonate, and the like. Also, salts based on mixtures of more than one of the foregoing types, such as dialkyl halovanadates, e.g., dibutyl chlorovanadate, and alkyl dihalovanadates, e.g., butyl dichlorovanadate, may be used. In many cases, preferred vanadium compounds are vanadium oxytrichloride, vanadyl or vanadium acetylacetonate, lower alkyl vanadates (alkyl groups of 1-4 carbon atoms) and halovanadates, especially chlorovanadates (monoand di-chloro).

Such a vanadium compound (1) is combined with an organometallic compound (2) to give the primary catalyst system in which at least one of the components '(1) and (2) must contain at least one halogen atom. Unfortunately such a conventional primary catalyst system, as indicated above, is frequently not as effective as would be desired, and may soon become incflicient or inactive. Also, it does not always provide a polymer having the desired properties.

The present invention is based on my surprising discovery that the primary catalyst system (a) is made more effective, (b) maintains its activity for a longer period, or (c) can be reactivated after it begins to slow down, if there is added a chemical (3) of the kind described. The added chemical unexpectedly serves as a regular of molecular weight, too.

While I do not desire to limit the invention to any particular theory of operation, it appears possible that the ability of the chemicals (3) to activate the primary catalyst is a consequence of an oxidizing action whereby the chemical (3) transforms at least a part of the vanadium into a valence state of +3 or more. Although the effect is not entirely understood, it appears as though the primary catalyst, as initially produced by the reaction of the vanadium compound (1) and the organometallic compound (2), is originally or may soon become inactive (because of the absence of vanadium in a valence state higher than +2) but transformation of some of the vanadium to a higher valence state by chemical 3) reactivates the catalyst. Whatever the explanation, it is indeed surprising that the chemical 3) has the here described beneficial effect on the primary catalyst. The benefits of the use of such a chemical 3) in accordance with the invention are especially important in making ethylene-propylene and ethylene-propylene-diene interpolymers. Such interpolymerization is, in general, much more difiicult to effect efficiently than the simple homopolymerization of, for example, ethylene.

It will be understood that, instead of mixing the vanadium compound with an organoaluminum compound directly to form the primary catalyst system, I may produce an equivalent system indirectly by the method of Carrick [1. Am. Chem. Soc. 82, 3883 (1960)], involving, for example, mixing tetraphenyltin, aluminum halide, and vanadium oxytrichloride, whereby phenylaluminum halide is believed to be formed in situ. Such a mixture may be activated in accordance with the present invention.

I emphasize that for purposes of the present invention the primary catalyst ingredients (1) and (2) should first be combined to form the primary catalyst system and that thereafter the primary catalyst system be acted upon by the chemical (3) as such. If the chemical (3) were appreciably prereacted with an individual component of the primary catalyst system prior to introduction of the third component, the desired highly active catalyst would not be obtained.

It will be understood that the empirical formula R AI X used to describe the organaluminum compounds is intended to include any of a wide variety of compounds or mixtures of compounds that might result, for example, from bringing together trialkylaluminum compounds, aluminum trihalides and/or alkylaluminum halides. For example, equimolar mixtures of monoalkylaluminum dihalide and dialkylaluminum monohalide, or equimolar mixtures of trialkylaluminum and aluminum trihalide, may be regarded as producing the alkylaluminum sesquihalide, R Al X A mixture of trialkylaluminum and dialkylaluminum rnonochloride may be regarded as providing a material of the formula R Al Cl. It should be noted that the formula R AI X as defined permits the use of trialkylaluminum as such, but not of aluminum trihalide as such. It is understood that such aluminum compounds are here represented by bimolecular formulas having two Al atoms.

The preferred primary catalyst system for use in producing binary and ternary copolymers of ethylene and propylene, in the present invention is a soluble catalyst (by which I mean soluble in organic hydrocarbons, including the monomers to be polymerized), formed by interaction of vanadium oxytrichloride and an alkylaluminum sesquihalide. By alkylaluminum sesquihalide I mean either the alkylaluminum sesquihalide as such, i.e., R Al X or a mixture containing a substantial amount of the sesquihalide. Such mixture may be represented by the empirical formula R Al X Where A+B=6, A is from 1.2 to 4.8, and B is correspondingly from 4.8 to 1.2, and may be formed by admixing appropriate amounts of dialkylalu- Ininum halide with alkylaluminum dihalide, or by mixing appropriate amounts of trialkylaluminum with aluminum trihalide. In the preferred alkylaluminum halides the alkyl group is a lower alkyl, typically of 1 to 4 carbon atoms, and the halogen is chlorine.

In preferred soluble primary catalyst systems, the molar ratio of aluminum to vanadium is at least 5:1, and preferably at least 10:1; higher ratios such as 20:1, 35:1, 50:1, etc., may also be used. If desired, even higher ratios of aluminum to vanadium, e.g., 200:1 or higher, may be employed, especially in those cases where the concentration of vanadium compound used is very small.

These preferred soluble primary catalyst systems are remarkable for their ability to form an amorphous, rubbery ethylene-propylene interpolymer of uniform composition, and particularly for their ability to form an amorphous ethylene-propylene-diene interpolymer that is sulfur-vulcanizable to yield a high quality rubber stock.

Although for many purposes the soluble catalyst compositions have been described as preferred, especially for the interpolymerization of ethylene and propylene, it will be understood that in other cases, notably the homopolymerization of propylene, the insoluble or heterogeneous type of catalyst may be used in my invention.

The amount of chemical (3) employed as activator for the primary catalyst system in accordance with the invention is, in general, not especially critical. Surprisingly small amounts of chemical (3), e.g., about 0.1 mole of chemical (3) per mole of vanadium compound (1), may be sufficient in many cases to produce a noticeable activating effect. Usually it is preferred to use somewhat larger amounts, typically from about 1 to about moles of chemical (3) per mole of vanadium compound (1), but it will be understood that considerably more chemical (3) than this may be employed, if desired. As much as about 50 moles, or more, can be employed, especially when the mole ratio of organometallic compound (2) to vanadium compound (1) is equal to or greater than 50 or when regulation of the molecular weight is desired. But in any case, the moles of chemical (3) should not exceed the moles of metal in the amount of organometallic compound (2) taken.

In any given case, the optimum amount of chemical (3) will depend upon the specific composition of the primary catalyst, and the particular chemical (3) used, as well as such variables as the exact polymerization procedure. More than one chemical (3) may be used if desired.

All or part of one or both of the primary catalyst ingredients (l) and (2) will generally be present in the monomeric material at the time the chemical (3) is added or within a short space of time after the addition of the chemical (3). In this way the chemical 3) does not have an opportunity to prereact appreciably with either of the primary catalyst ingredients in the absence of the other. Prolonged contact of the chemical (3) with one of the primary catalyst ingredients in the absence of the other results in lower polymer yields. One method for carrying out the invention is to combine the primary catalyst ingredients (1) and (2) in the presence of at least a portion of the monomer or monomers and then to add the chemical (3). Another method is to premix the primary catalyst ingredients in the absence of monomers and thereafter to combine the mixture with monomers and chemical (3). In addition to the above methods of delayed addition of chemical (3), one may add all three catalyst ingredients (1), (2) and (3) simultaneously to the monomer or monomers. Another method which can be used is to add the chemical (3) to either of the primary catalyst ingredients (1) or (2) just prior to the addition of the other; however, the other must then be added promptly, before appreciable reaction takes place between 3) and the primary ingredient which was added first. In all cases the monomers need not be present until the third ingredient is added.

As indicated previously, the chemical (3), added to the conventional catalyst system in accordance with the invention, is inherently capable of performing two important functions: (A) activation, and (B) regulation or modification.

To appreciate the activation function (A), it is helpful to consider first the behavior of the soluble primary catalyst system as conventionally used. In conventional practice the activity of the soluble catalyst, i.e., the rate at which the catalyst produces polymer is often very satisfactory at the start, but falls off more or less rapidly as the polymerization progresses. However, addition of a small quantity of an activator chemical (3) according to the present invention prevents such decay in activity and restores the activity of the catalyst. Likewise the addition of such activator to a heterogeneous catalyst system increases its activity.

As for the modifying or regulating function (B), the conventional catalyst system tends to give polymer of very high molecular weight. This feature is detrimental to the processing qualities of the polymer. However, the molecular weight of polymer formed when the chemical (3) is added to the catalyst system may be remarkably reduced, so that an easily processable polymer is readily obtained. In fact, liquid polymers can be obtained in this way.

From the standpoint of using the chemical (3) essentially for its activating effect, the usual practice is to add it after the catalyst has become partially spent, thereby revitalizing the catalyst. Thus, repeated small additions of chemical (3) may be made as the polymerization proceeds, to maintain optimum catalyst efficiency throughout the reaction.

From the standpoint of using the chemical (3) essentially for its regulating or modifying effect, it may be added at any time after which it is desired to produce low molecular weight material. For instance, if it is desired to make polymer having a regulated molecular weight over the entire reaction period, addition of chemical (3) is begun at the start of the polymerization. On the other hand, delayed addition of chemical (3) will result in the production of relatively high molecular weight polymer prior to the addition and lower molecular weight polymer subsequent to the addition, so that the final product is a mixture of high and low molecular weight polymers. This may be desirable under some circumstances. The preferred method, both for best yields and for optimum control of molecular weight, is to add the chemical (3) continuously or in small increments as the polymerization proceeds rather than to add a large amount all at once.

The polymerization process is conveniently carried out in an inert solvent, although an added solvent is not essential as the monomers being polymerized may serve as the solvent. In general, the normal solvents used in ionic coordination type polymerizations may be used. These include the aromatic hydrocarbons, aliphatic hydrocarbons, chlorobenzene, tetrachloroethylene, and any other solvents which will not destroy the catalyst. Furthermore, the procedure may otherwise be the same as in conventional practice as far as such details as temperature of polymerization, pressure, concentration of catalyst, and the like, are concerned.

One preferred practice of the invention contemplates continuously interpolymerizing ethylene, propylene and a diene such as dicyclopentadiene. The aforementioned is accomplished by introducing the primary catalyst ingredients (1) and (2) separately into a solution of the monomers in an inert organic solvent. The resulting solution is passed continuously through a polymerization zone, wherein the chemical (3) is added. A stream containing terpolymer is withdrawn from the polymeriza tion zone. These steps may be repeated in one or more subsequent polymerization zones into which the reaction stream, withdrawn from the previous polymerization zone, is successively introduced. There may be incrementally or continuously introduced into each zone more of the primary catalyst ingredients, and/or more activatorregulator (3), as required, to maintain the system at peak efiiciency consistent with economical utilization of catalyst and production of terpolymer of the desired average molecular weight. Additional amounts of one or more of the monomers may be introduced in each subsequent reaction zone, if desired. The stream issuing from the final reaction zone, in the form of a thick solution, or cement, may be processed in the usual way to separate the polymer and remove catalyst residues.

Schreyer, U.S. 2,962,451, teaches catalysts made by mixing a vanadium compound in which the vanadium is in a high valence state, i.e., +3 or higher, with an organometallic compound in amount sufficient to reduce the vanadium, at least in part, to a valence state of less than +3. While such a catalyst may be activated in accordance with the present invention, it is not essential for purposes of the invention that the vanadium compound employed have a valence of at least +3, although it is preferred. On the contrary, vanadium compounds in which the vanadium has a valence of less than +3, such as vanadium dichloride, may be used. However,

it will be understood that in such a case the product obtained by mixing the vanadium compound (1) with the organometallic compound (2) does not become an active catalyst for preparing ethylene copolymers until the chemical (3) of the invention is added. This is in conample follows known catalyst addition procedures and yet no reaction has taken place.

At this point the dropwise addition of a benzene solution containing 0.1 millimole of p-dimethylaminonitrosobenzene was begun. The temperature started to rise imtrast to the product obtained by mixing a vanadium +3 mediately, rising as much as 19. It took 25-30 minutes compound with the organometallic compound, which to add all the activator. After 30 minutes, 15 cc. of isoproduct is an active catalyst for ethylene copoly'merizapropanol was added to destroy any active catalyst. The tion even before the chemical (3) is added. Although solution was then treated with 10cc. of a 5% solution of vanadium compounds in which the vanadium has a valence 1 0 antioxidant, 2,2'-methylene-bis(4 imethyl 6' t butylof less than +3 may be used in the invention, it is prephenol), in toluene, and the polymer was flocculated in ferred to use vanadium compounds in which the vanadium methanol. After being washed with additional methanol has a valence of at least +3. Such compounds are particcontaining antioxidant the polymer was vacuum-dried at ularly advantageous from the standpoint of the described 40 C.; yield, 13.7 g. In this example the catalyst efilcontinuous polymerization procedure in which the catciency wa 805, No crystallinity could be detected by alyst is introduced into a first polymerization zone With- X-ray. The weight ratio of propylene to ethylene in the Out Chemical and the Chemical is added polymer was 39/61, and the intrinsic viscosity (at 135 subsequently after a certain amount of polymerization C, i t t li was L90. has taken place. Following the same procedure as described above (ex- As will be apparent from data given below, he inven cept that 700 ml. of benzene was used instead of 350 tion is highly critical in the sense that if a titanium-based nil.), 0.1 millimole of N-nitrosodiphenylamine was used primary catalyst were to be used in place of a vanadi mas the activator instead of p-dimethylaminonitrosobenbased primary catalyst, the chemical (3) of the invenzone and a yield of 13.0 g. of rubbery ethylene-propylene tion would not be effective. Chemicals seemingly closely olymer wa obtained. The catalyst eificiency (g. of related to the present chemicals (3) are not effective in olymer per g. of cocatalyst, VOCl was 750. the invention. Thus, data given below shows that mono- In a similar manner, other aryl nitroso compounds or di-ketones have no activating effect. On the other hand, u h as 4-nitr0sodiphenylarnine, o-nitrosotoluene, and N- the presence of other polar groups, either electron-withnitroso amines h as N it N- th 1 i1i N 4- drawing of electron-donating, in the Present i als dinitroso-N-methylaniline, etc., and quinones such as 1,4- (3) does not inhibit their ability to activate the catalyst naphthoquinone, 2,6-naphthoquinone, 9,10-anthraqui- (see Example 1). none, 1,2-naphthoquinone, o-benzoquinone, p-benzoqui- The following examples will serve to illustrate the nonepheniamhrengquinone,and th lik may b l d practice of the invention in more detail. The efiicieucy as activators in accordance with the invention. Examples of the Catalyst is Calculated in all examples as grams of of the use of still other quinones are presented as Expolymer produced per gram of cocatalyst, VOCl 5 amples 2-8.

example shows activation of a IE- nixed catalyst Examples 28 211B herewith set forth to illustrate various b means f nitroso compounds h as -di h 1 i quinones that are operable as catalyst activators in acnitrosobenzene and N-nitrosodiphenylamineinthe formaeefdenee With the invention during the formation Of i f ethy1ene.pmpy1ene bb ethylene-propylene and ethylene-propylene-diene rubbers. 'In a one-liter flask equipped with condenser, stirrer, In the eXamples below, the Procedure was substantially thermometer, dropping funnel and a tube for the subas described in the first P of Example 1 P that surface feeding of gaseous monomers, 350 cc. of purified in Examples 6 and 709 f nz n Was s d as benzene at ambient temperature was saturated at atmos- Solvent in the reaction medium in Place of 350 The pheric pressure by an equimolar feed consisting of hightechnique of mixing the P y Catalyst ingredients in the purity ethylene and propylene, using a total feed ratio of absence of monomers, PremiXiIlg, Was used in Order t0 f 1it per i t With interrupting h monomer accentuate the difference between the relatively poor yields feed, 16 ml. of a benzene solution containing 1 milli- Obtained in the absence of Chemical as ill the PriOr mole of Et Al Cl and 0 .1 millimole of VOCl (premixed 11ft, and the v y high yields obtained by the use of catalyst) which had been allowed to age 15 min. in an h m al (3) in a daIICe With my invention (Examples argon atmosphere was added. After five minutes the tem- 2, 3 and 68). Thus, this method affords a good screenperature had risen only about 2 C. Thus far the exing test for activators.

Example No 2 3 4 5 6 7 3 Activator/mmole A/0.1 1.3/0.2 C/0.1 E/0.1 C/0.1 Mole ratio activator/vanadium 1 1 1 Diene D F Milliliters of dieue Reaction temperature range, C Yield, g Elficioucy Percent crystallinity, X

W eight ratio P/E, infrared 1 0.2 mole of this activator was added, but it was only partially soluble.

B -Accnaphthenoquiuone.

C B eta-Inothylanthraquinoue.

1 i)icyclopoutadieno,

ll-cthyH ,1 l-tritlecttdiol to.

In a similar manner, the activation method of the invention may be applied to catalyst systems produced from other vanadium compounds such as vanadium dichloride, vanadium trichloride, vanadium tetrabromide, vanadium tetrachloride, butyl vanadate or other alkyl vanadates, vanadyl acetylacetonate, vanadium acetylacetonate, dibutyl chlorovanadate, butyl dichlorovanadate, and the like.

EXAMPLE 9 none. It is another example of molecular weight regulation.

In a two-liter flask equipped as in Example 1, the procedure of Example 10 was followed except that betamethylanthraquinone was used as the chemical (3), for purposes of molecular weight regulation.

Yield grams 17.4 P/E 34/66 I.V. (135 in tetralin) 2.37

For comparison, a control run was made, identical to Examples 10 and 11, except that no chemical (3) regulator was introduced, with the following results:

Yield grams 4.8 E/P 69/31 I.V. (135 in tetralin) 4.50

Example No 9A Catalyst Mmoles of catalyst. Cocatalyst Mmoles of cocatalyst Al/vanadium ratio Solvent/ml Total feed, 1iters/min Feed ratio, E/P Mmoles of chemical (3)... Temperature, C Reaction time, min

Intrinsic viscosity (135 C. in tertalin). Percent crystallinity, Xray Weight-ratio P/E, infrared 1 3/1 Benzene/350 Benzene/352 3/1 B (marine/352 EXAMPLE 10 Examples 10 and 11 illustrate the use of chemical (3) as a molecular weight regulator.

This example illustrates the use of a high ratio of chemical (3) to vanadium (50/1), using N-nitrosodiphenylamine. This condition leads to molecular weight regulation.

In a two-liter flask equipped as in Example 1, 700 cc. of purified n-heptane was saturated at atmospheric pressure and ambient temperature by an equimolar feed of high purity ethylene and propylene, using a total feed rate of 4 liters per minute. Without interrupting the monomer feed, one millimole of Et Al Cl and 0.02 millimole of VOCl (as n-heptane solutions) were added consecutively (Al/V=l00/ 1). Immediately, the dropwise addition of 1.0 millimole of N-nitrosodiphenylamine (as 60 ml. of nheptane solution) was begun and continued throughout the polymerization (30 min.). After 30 minutes, 15 ml. of isopropanol was added to destroy the active catalyst. The solution was then treated with 10 cc. of a 5% solution of antioxidane, 2,2-methylene-bis (4-methyl-6-t-butylphenol) in toluene, and the polymer was flocculated in one liter of a 50/50 (by volume) mixture of methanol and acetone. After being chopped in a Waring Blendor, the polymer was vacuum dried.

Yield grams 11.5 P/E /70 I.V. (135 in tetralin) 3.15

The data show the low yield, and the: undesirably high molecular weight as measured by the intrinsic viscosity, which result when no regulator chemical (3) is used.

Similarly, other alkylaluminum halides such as diethylaluminum chloride or ethylaluminum dichloride may be substituted in the foregoing examples. In place of using alkylaluminum halides or trialkylaluminums as the organometallic component of the primary catalyst system in practicing the invention, there may be employed Grignard reagents, such as phenylmagnesium bromide, ethyl magnesium chloride, and the like, or lithium aluminum tetraalkyls, such as lithium aluminum tetraethyl, and the like. Similarly, the system of Carrick (tetraphenyltin-l-aluminum halide+vanadium compound) may be used as a means of providing in situ a combination of organoaluminum halide and vanadium compound to be activated in accordance with the method of the invention.

In place of copolymerizing alpha-olefins by the method of the invention, the alpha-olefin, e.g., ethylene, propylene, etc., may be homopolymerized by the present method, too.

Another control experiment was run to show that an activator chemical (3) of the present invention is not effective with a titanium-based primary catalyst system, in contrast to its effectiveness with a vanadium-based catalyst. In this run the chemical (3) was beta-methylanthraquinone. It was added over the duration of the run, which was carried out in accordance with the procedure of the first part of Example 1.

Run No .1

Catalyst Mmoles a;attest:11111111111111:

Cocatalyst Mmoles of cocatalyst Catalyst/co-catalyst ra E/P mole ratio (feed)... Total feed, liters/min Mmoles oi activator... .1 Activator/coeatalyst molar ratio Reaction temperature, C Reaction time, min Solvent EXAMPLE 1 1 This example illustrates the use of a high ratio of chemical (3) to vanadium (50/ 1), using beta-methylanthraqui- Yield of polymer, g

In contrast, the following experiment shows that monoand di-ketones do not function as activators with the primary catalyst system of this invention.

Both of the following runs, which should be compared 1 1 with Examples 2-8 (of which Examples 4 and are blank runs), were carried out in accordance with the procedure as described in Example 1, but using ketones as the additives.

Having thus described my invention, what I claim and desire to protect by Letters Patent is:

1. A method of copolymerizing ethylene and propylene comprising contacting said monomers with a hydrocarbon soluble catalyst system made by mixing (1) a vanadium salt,

(2) an organometallic compound selected from the group consisting of those of the formulae (a) RMgX, where R is an alkyl or aryl radical and X is a halogen atom, (b) LiAlR where R is as above defined, and (c) R AI X where R and X are as above defined, A is a number from 2 to 6, B is a number from zero to 4, and A+B=6, and (3) material selected from the group consisting of aryl nitroso compounds and quinones,

the moles of (3) being equal to or less than the moles of metal in the amount of (2) taken, at least one of said substances (1) and (2) containing at least one halogen atom the mole ratio of (2) (1) being in the range from 5: 1 to 200:1, the said material (3) being added subsequently to combining (1) and (2), and the amount of (3) being at least 0.1 mole per mole of (1).

2. A method as in claim 1 in which there is also present, along with the said monomers, a copolymerizable diene whereby a terpolymer of ethylene, propylene and said copolymerizable diene is formed.

3. A method for copolymerizing ethylene and an alphaolefin containing at least three carbon atoms, to form an amorphous, rubbery copolymer comprising contacting said monomers with a catalyst made by mixing a primary catalyst comprising (1) a vanadium salt, and

(2) an organometallic compound selected from the group consisting of those with the formulae (a) RMgX, where R is an alkyl or aryl radical and X is a halogen atom, (b) LiAlR where R is as previously defined, and (c) R AI X where R and X are as previously defined, A is a number from 2 to 6, B is a number from zero to 4, and A+B=6, and thereafter introducing to the monomer-catalyst mixture in measured amount over a period of time during the polymerization reaction (3) a material selected from the group consisting of aryl nitroso compounds and quinones, the mole ratio of (2) (1) being in the range from 5:1 to 200:1, and the amount of (3) being at least 1 mole per mole of (1) but not greater than the moles of metal in the amount of (2) taken, at least one of said substances (1) and (2) containing at least one halogen atom, and the said catalyst being soluble in hydrocarbon solvents.

4. A method of making a sulfur-vulcanizable, unsaturated, amorphous interpolymer of ethylene, propylene, and a copolymerizable diene comprising contacting the said monomers with a hydrocarbon-soluble catalyst composition formed by mixing vanadium oxytrichloride, an alkylaluminum chloride in which the alkyl group has from 1 to 4 carbon atoms, and a nitroso compound selected from the group consisting of p-nitrosodimethylaniline, 4-nitrosodiphenylamine, nitrosobenzene, o-nitrosotulene, N-nitrosodiphenylamine, N-nitroso-N-methylaniline and N,4-dinitroso-N-methylaniline and N,4-dinitroso-N-methylaniline, the mole ratio of aluminum to vanadium being in the range from 5:1 to 2 00: l, the mole ratio of nitroso compound to aluminum being not greater than unity, the nitroso compound being added subsequently to combining the said aluminum and vanadium compounds, and the amount of nitroso compound being at least one mole per mole of vanadium.

5. A method as in claim 4 in which the nitroso compound is p-dimethylaminonitrosobenzene.

6. A method as in claim 4 in which the nitroso compound is N-nitrosodiphenylamine.

7. A method of making a sulfur-vulcanizable, unsaturated, amorphous interpolymer of ethylene, propylene, and a copolyrnerizable diene comprising contacting the said monomers with a hydrocarbon-soluble catalyst composition comprising vanadium oxytrichloride, an alkylaluminum chloride in which the alkyl group has from 1 to 4 carbon atoms, and a quinone selected from the group consisting of p-benzoquinone, tetrachloro-p-benzoquinone, 1,4-naphthoquinone, 2,6-naphthoquinone, 2,3-dichloronaphthoquinone, 9,10-anthraquinone, beta-methylanthraquinone, 1,2-naphthoquinone, o-benzoquinone, acenaphthenequinone and phenanthrenequinone, the mole ratio of aluminum to vanadium being in the range from 5:1 to 200:1, the mole ratio of quinone to aluminum being not greater than unity, the quinone being added subsequently to combining the said aluminum and vanadium compounds, and the amount of quinone being at least one mole per mole of vanadium.

8. A method as in claim 7 in which the quinone is tetrachloro-p-benzoquinone.

9. A method as in claim 7 in which the quinone is beta-methylanthraquinone.

10. A method as in claim 7 in which the quinone is acenaphthenequinone.

11. A method as in claim 7 in which the quinone is 2,3-dichloronaphthoquinone.

12. A catalyst composition formed by the mixing (1) a vanadium salt,

(2) an organometallic compound selected from the group consisting of those of the formulae (a) RMgX, Where R is an alkyl or aryl radical and X is a halogen atom, (b) LiAlR where R is as above defined, and (c) R AIX Where R and X are as above defined, A is a number from 2 to 6, B is a number from zero to 4, and A+B=6, and (3) a material selected from the group consisting of aryl nitroso compounds and quinones,

the mole ratio of (2) (1) being in the range from 5:1 to 20 011, and the moles of (3) being equal to or less than the moles of metal in the amount of (2) taken, at least one of the substances (1) and (2) containing at least one halogen atom, the said catalyst being soluble in organic hydrocarbon solvents, the said material (3) being added subsequently to combining (1) and (2), and the amount of (3) being at least 0.1 mole per mole of (1).

13. A method of producing an activated catalyst system comprising mixing (1) a vanadium salt,

(2) an organometallic compound selected from the group consisting of those of the formulae (a) RMgX, where R is an alkyl or aryl radical and X is a halogen atom, (b) LiAlR where R is as above defined, and (c) R AI X where R and X are as above defined, A is a number from 2 to 6, B is a number from zero to 4, and A+B='6, and

(3) material selected from the group consisting of aryl nitroso compounds and quinones, at least one of said substances (1) and (2) containing at least one halogen atom, the mole ratio of (2) :(1) being in the range from 5:1 to 200:1, the amount of (3) be- 13 14 ing at least 0.1 mole per mole of (1) but not greater than 3,045,001 7/1962 Berger.

the moles of metal in the amount of (2) taken, the said 3,210,332 10/1965 Lyons et al. catalyst being soluble in organic hydrocarbon solvents, 3,288,773 11/1966 Harban et a1. and the said material (3) being added subsequently to combining (1) and (2). 5 JOSEPH L. SCHOFER, Primary Examiner.

References Cited R. S. BENJAMIN, Assistant Examiner.

UNITED STATES PATENTS US. Cl. X.R.

2,962,451 11/ 1960 Schreyer 260-93.7 260-882, 94.9; 252429 3,000,866 9/1961 Tarney 260-79.5 10 

